Automatic control of alternating current-direct current motorgenerator set



p 9, 1947. R. R. DYSART 2,427,127

AUTOMATIC CONTROL QP ALTERNATING CURRENT-DIRECT CURRENT IOTOR-GENERATOR SET Filed April 25, 1944 4 Sheets-Sheet 1 4 Sheets-Sheet 2 unnsu'r cunmsm MOTOR-GENERATOR sn'r Sept. 9, 1947. R. R. DYSART AUTOIATIC CONTROL OF ALTERNATING Filed April 25. 1944 a F b 2 f w a n 2 A 4 H fi W Wu M. y 2 LA a w 2 W a Y m L DM B nvvsmun 4 mm RDmARr p 9, 1947. R. R. DYSART 2,427,127 AUTOIATIC CONTROL OF ALTERNATING CURRENT-DIRECT 7 -CURRENT MOTOR-GENERATOR SET Filed April 25, 1944 4 Sheets-Sheet 3 llVVDVTZIR- Mm R. Dysmr fwd ATTDRV Y Sept, 9, 1947.

Aurommc comm or ALTERNATING CURRENT-DIRECT CURRENT MOTOR-GENERATOR SET R. R. DYSART Filed April 25, 1944 4 Sheets-Sheet 4.

/w/vron RONALD P. DYSART A TT'OI v: r

Patented Sept. 9,1947

AUTOMATIC CONBIEQL F ALTERNATING CURRENT-DIRECT CURRENT MOTOR- GENERATQR SET Ronald it. Dysart, panama, cane, assignor to Frank H. Varncy, an individual doing business as D-W. Welding Controls, @ahland, (Calif.

Application April 25, 1944, Serial No. 532,635

(El. Mi -123) 3 Claims.

My invention relates to automatic control means for electric arc welding machines.

One of the problems in the operation of these machines is the waste of power, consumed during the periods when welding is not actually bein done. In the average machine the welder is considered very good if his are time, that is, ac tual welding time, is 25% of his total hours woriaed. Thus, in an 3 hour day, 75% of the time or 6 hours, the machine is running and doing no productive work.

The principal object of my invention is to pro vide a control means which effects the automatic starting of the welding machine, merely touching the welding rod to the grounded work, and which stops the machine after a predetermined time 111 terval has elapsed following completion of a welding operation. This results in conservation of electric power, which is an advantage to the owner from an'economic point of view and to the Nation from the standpoint of conservation of natural resources.

Another object of my invention is to provide a solution to the problem of checking on how effectiveuse a welder is making of a machine.

This feature of production totalizing is a contrioution of substantial value for increasing production efiiciencies and reduction of construction manhours. Y

My device may be, manufactured so that a sin gle unit will perform both the automatic starting andstopping function as well as totalizing of the are time or it may be built so that either of the features are obtainable in individual single units. The unique design makes it inherently possible first to utilize the unit embodying either feature and then later to add the second feature.

Other objects and advantages of my invention will become apparent from the following description and drawings which are furnished pursuant to U. S. Rev. St. 4888 as illustrative embodiments, and expressly without any intention of limiting the interpretation of the appended claims to these specific forms of apparatus.

In the drawings,

Fig. 1 ma diagrammatic view of one form of device showing thecircuits in the ofi or idle position;

Fig. 2 is alike view showing the circuits immediately after initial contact of the welding Fig. 5 shows a further modification in the timing recorder.

Referring now to Fig. it will be seen that the basic elements or the combination there illustrated include the following:

Conductors it, 82 and represent a suitable alternating current supply line. A motor generator set, consisting in this instance of alternating current driving motor it and a direct current welding generator it, has the terminalsof the motor connected to the conductors it, ill and it. A suitable magnetically operated starter switch'fiil is provided, which when closed connects conductorsi 0, ill and it} with conductors it, it, This starter switch is shown provided with conventional interlock contacts or switch Ell, which is operated in conjunction with the other movable parts of the switch. A suitable alternating current transformer i2 is provided, having one side of its primary connected to current supply line it by conductor 23, and having the other side of its primary connected by conductor fiil to conductor 2'71, and from thence to the current supply line i i. Thus this transformer is continuously excited with alternating cur connected in series with a magnet 38 and directly across a reactor it, in the welding circuit. Thus one side of the secondary winding 40 is connected by conductor 35 to magnet 38, and the other side of this magnet connects by conductors 35, 34' to conductor iii in the welding circuit, which in turn connects to one side of the reactor The other side of winding Ml is connected by conductor 8'! to conductor 32, which is likewise in the welding circuit and which connects to one side of reactor ll. The welding circuit itself, or load circuit'as it may be termed, includes the welding generator grounded, conductors 30, 3!, reactor 5|, conductor ill, conductor 33, welding rod ill, and the grounded work it. Reactor M is of such a value that it ofier very little resistance to the direct current of the welding circuit.

The control circuits connected to the electromagnet 48 include a starting control circuit which can be traced as follows: One side of magnet 48 is connected to conductors 44, 43 to one contact of switch it. The movable element of this switch is connected by conductor 25 to one side of the switch 2|. switch connects with a conductor 44. In addition to the circuit just specified a circuit is provided by way of conductor 26 which connects with it, one side of which is The other side of this 3 conductor fl. switch It, and conductors 42, II

which lead to the current supply line H. Briefly it may be explained at this point that switch II when closed performs a starting function in effecting closing of the main switch II, whereas switch II when opened performs a stopping function in that it effects deenergization of magnet 48 with opening of the main switch. A timing motor 52 i also provided and is adapted to be energized by having its one side connected by conductor 53 with conductor I1, and its other side connected by conductor 54 to a midpoint on the primary of transformer 22. The shaft of this motor has a sliding clutch member 55 splined upon the same.

In addition to the above; timing means is provided utilizing a gear rack 58. together with a pinion 51 which is loosely mounted on the motor shaft. Clutch member 58 is rotatable with pinion 51, and is engageable by the clutch element 55. when so engaged rack 58 is raised at a predetermined rate until it opens the normally closed switch 50. Clutch element 55 is shifted by an armature 80-, which in turn is actuated by the electromagnet 38 and the return spring 18. A suitable counter 8| can be rigidly mounted in the frame, or it can be carried on the armature 82 as shown.

The means for placing the counter in operation is the clutch member 55, which is engaged with a corresponding clutch member 63 in response to the full force of the electromagnet 38. The armature B2 is moved by coil 14 in circuit 15, 34, 30 and I6 whenever the generator is rotating and welding voltage exists. Springs I1 and 18 return armatures 82 and 50 to their other positions when their respective electromagnets are deenergized.

It may be explained that many types of motor starter switches are available on the market which can be used with my system for the main switch 20. Such switches are operated magnetically and are supplied with control circuits and start and stop contacts for controlling the operating magnet (corresponding to magnet 48). It

should be understood that switch either shunts or takes the place of the conventional start contact, while switch 50 is connected in series with or takes the place of the conventional stop contacts. The circuits connecting these switches or contacts with the magnet 48 and the source of current supply can be termed start and stop control circuits.

The operation of the above device is as follows:

When the main disconnect switch (not shown), which supplies energy to the A. C. lines ll, l2, i3 is closed, the transformer 22 is energized thereby placing its secondary electromotive force across the relay 38 and across the reactor 4| which is a specially designed reactor suitable to permit the flow of the entire output of the welding generator. Now turn to Fig. 2 of the drawings to see the next step. When the operator touches the welding rod to the grounded work ll relay 38 becomes fully energized and operates armature 60. Armature 80 moves the ed in my device.

clutch 55 to the left. disengaging clutch faces 55,

58 and also closes the.switch 5| which closes the motor-generator circuit magnetic switch 20 and starts the motor-generator set. The switch 5| is shown as a single pole positioning switch constructed so that when it is closed it remains closed until opened by the rod 12 on armature.

62. This reduce the possibility of burning contact points when coil 35 is momentarily enerswitch 20.

gized. However, I have found that a normally open type switch in place of switch ll works satisfactorily. Now turn to Fig. 3 of the drawings. Almost instantly after switch II is closed the motor generator set comes up to full speed. Then the voltage across the generator comes up to the preset value and energizes coil 14, thereby attracting armature 82. Armature l2 performs two functions at this point in the operation. It resets (opens) the switch I and it positions the counter 8| for properly enlasing the clutch members 83 and 55. The parts will stay in this position so long as the welding continues.

when the welding ceases, the parts will be in the position shown in Fig. 1 except that switch is will be closed. Clutch faces 55 and 58 will be engaged and the motor 52 which turns shiftable clutch 55 at a suitable speed such as (1 R. P. M.) will cause clutch face 58 to turn the pinion 51 and raise the gear rack 58. If the parts continue in this position for the predetermined time, the rack 56 will lift the switch 50 into the dotted line position. This arrangement whereby the rack 58 lifts the switch member 50 is for the purpose of providing a time delay interval before stopping the motor generator set by opening An adjustment is provided by the screw 19 so that the time delay interval may be chosen from a few seconds to several minutes time before the rack 56 will open switch 50. If welding is not resumed during the predetermined time delay interval, the rack 58 will raise and open the normally closed switch 50, thereby deenergizing the magnetic switch coil 45 and stopping the motor generator set l4, l5.

If the welding electrode 10 is again touched to the work and an arc is established before the time interval has elapsed coil 38 will become fully energized, since reactor 4| will become saturated when the D. C. output of the generator i5 is used. Armature then will disengage clutches 55 and 58, and will reengage clutch 55 with clutch 63. The gear rack 56 will then drop and reset to its original setting against screw 18 and the clutch 63 will turn the counter 8|. Counter 8| is suitably chosen to count the desired unit of time. Then so long as the arc remains established with the work the parts will be in the position of Fig. 3.

An are time anti-stealing feature is incorporat- For normal arc voltages, coil 14 hold armature 62 in position for the counter H to record are time. However, if an operator attempt to record a false are time by shorting his rod 10 to the work II, the voltage across coil 14 will drop below the normal arc voltage and will release the armature 52, thereby diseng ging clutches 53 and 55.

The device may be used as an are time totalizer only or it may be used as a starter and stopper only.

The modification shown in Fig. 4 substitutes a dashpot time delay means for the rack and pinion device used in Figs. 1 to 3. Also in place of the clutch for driving the counter, I have substituted a synchronous motor-driven time means which will record the time elapsed when the elecwill allow rapid inward flow of air into chamber 84 as the solenoid 86 pulls the plunger rod downturned to contact with the work before the spring 83 can push the rod -62 through its full upward stroke, the rod 82 will open normally closed switch 50 and the motor-generator set will shut down. Then if the operator again touches the electrode 18 to the work H the solenoid 86 will allow switch 58 to close and will close switch which will energize the motor-generator magnetic starting switch 48.

The modification shown in F18. 5 is like that shown in Fig. 4 except that in place of a syn-- chronous electric timing means, I have substinet serving when energized to effect closing of tuted a spring or weight actuated time piece 90 which is equipped with a suitable brake 9| having an actuating lever 82. adapted to be engaged by the plunger rod 82 on its downward stroke. Thus whenever the electrode 10 is in' contact with the work H and the solenoid 86 has drawn rod 82 downwardly, the brake 9| will be released and welding time will be recorded on the clock 80.

As stated at the outset, it is not my intention to limit my invention to the devices used herein to illustrate one embodiment and a modification or two.

What I claim is:.

an alternating current motor adapted to be connected to alternating supply lines through a starter switch and a direct current generator driven by the motor and connected to a load circuit, the starter switch having control circuits said starter contacts, the secondary of the transformer being connected across said reactor in series with said magnet whereby when the load circuit is closed the alternating current flowing in the secondary of the transformer is increased to operate said magnet, and timing means effective to'open said stop contacts a predetermined time interval following-opening of the load circuit.

3. In an electrical welding system of the type having an alternating current driving motor adapted to be connected to alternating current supply lines through a main'starter switch and a direct current welding generator driven by the motor and connected to an arc welding circuit, the starter switch having control circuits associated with the same for causing closing and opening of the main starter switch in response to closing and opening of start or. stop contacts; a reactor of relatively low direct current resistance connected in series with the load circuit, a transformer having its primary supplied with alternating current from said current supply lines, means serving to effect closing of said start 1. In'an electrical system of the type having contact including a magnet adapted to be energized, the secondary of the transformer being connected across said reactor in series with said -magnet whereby when the load circuit is closed the current flow in the secondary circuit of the transformer is increased to operate said start for causing closing and opening of the main switch in response to closing and opening of start and stop contacts, a reactor of relatively low direct current resistance connected in series with the load circuit,'a transformer having its primary supplied with alternating current from said current supply lines, and means including a magnet serving when energized to effect closing of said starter contacts, the secondary of the transformer being connected across said reactor in series with said magnet whereby when the load circuit is closed the alternating current flowing in the secondary of the transformer is increased to operate said magnet.

2. In an electrical system of the type having an alternating current motor adapted to be connected to alternating supply lines through a starter switch and a direct current generator driven by the motor and connected to a load circontact, and means effective to open the stop contacts to cause opening of the main switch at the end of a predetermined interval following complete opening of the welding circuit.

RONALD R. DYSART.

REFERENCES crrnn The following references are of record in the file of this patent:"

Duis Jan. 25, 1944 

